Asme ptb 8 2014 (american society of mechanical engineers)

ASME PTB-8-2014 Procurement Guidelines for Metallic Materials Copyright c 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014 PROCUREMENT GUIDELINES FOR METALLIC MATERIALS Prepared by: Elmar Upitis Upitis & Associates, Inc Copyright c 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME Date of Issuance: September 12, 2014 This document was prepared as an account of work sponsored by ASME Pressure Technology Codes and Standards (PTCS) through the ASME Standards Technology, LLC (ASME ST-LLC) Neither ASME, the author, nor others involved in the preparation or review of this document, nor any of their respective employees, members or persons acting on their behalf, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness or usefulness of any information, apparatus, product or process disclosed, or represents that its use would not infringe upon privately owned rights Reference herein to any specific commercial product, process or service by trade name, trademark, manufacturer or otherwise does not necessarily constitute or imply its endorsement, recommendation or favoring by ASME or others involved in the preparation or review of this document, or any agency thereof The views and opinions of the authors, contributors and reviewers of the document expressed herein not necessarily reflect those of ASME or others involved in the preparation or review of this document, or any agency thereof ASME does not “approve,” “rate”, or “endorse” any item, construction, proprietary device or activity ASME does not take any position with respect to the validity of any patent rights asserted in connection with any items mentioned in this document, and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable letters patent, nor assume any such liability Users of a code or standard are expressly advised that determination of the validity of any such patent rights, and the risk of infringement of such rights, is entirely their own responsibility Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code or standard ASME is the registered trademark of The American Society of Mechanical Engineers No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher The American Society of Mechanical Engineers Two Park Avenue, New York, NY 10016-5990 ISBN No 978-0-7918-6947-5 Copyright © 2014 by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All Rights Reserved Printed in the U.S.A Copyright c 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials TABLE OF CONTENTS Foreword v INTRODUCTION SCOPE ASME ADOPTION OF MATERIAL SPECIFICATIONS 3.1 ASME Material Specifications 3.2 ASTM Material Specifications 3.3 Dual Marked Materials 4 GENERAL REQUIREMENTS IN MATERIAL SPECIFICATIONS FOR VARIOUS PRODUCT FORMS 4.1 SA-20, General Requirements for Steel Plates for Pressure Vessels 4.2 SA-788, General Requirements for Steel Forgings 4.3 SA-961, Common Requirements for Steel Flanges, Forged Fittings, Valves, and Parts for Piping Applications 4.4 SA-530, General Requirements for Specialized Carbon and Alloy Steel Pipe 10 4.5 SA-450, General Requirements for Carbon and Alloy Steel Tubes 11 4.6 SA-703, General Requirements for Steel Castings for Pressure-Containing Parts 12 4.7 SA-480, Specification for General Requirements for Flat-Rolled Stainless and HeatResisting Steel Plate, Sheet, and Strip 13 4.8 SA-1016, Specification for General Requirements for Ferritic Alloy Steel, Austenitic Alloy Steel, and Stainless Steel Tubes 14 4.9 SB-248 General Requirements for Wrought Copper and Copper-Alloy Plate, Sheet, Strip and Rolled Bar 15 4.10 SB-249/SB-249M General Requirements for Wrought Copper and Copper-Alloy Rod, Bar, Shapes, and Forgings 15 4.11 SB-251, General Requirements for Wrought Seamless Copper and Copper-Alloy Tube 15 4.12 SB-751, General Requirements for Nickel and Nickel-Alloy Welded Tube 15 4.13 SB-775, General Requirements for Nickel and Nickel-Alloy Welded Pipe 16 4.14 SB-824, General Requirements for Copper Alloy Castings 16 4.15 SB-829, General Requirements for Nickel and Nickel Alloys Seamless Pipe and Tube 16 4.16 SB-906, General Requirements for Flat-Rolled Nickel and Nickel Alloys Plate, Sheet and Strip 16 ADDITIONAL CONSIDERATIONS FOR MATERIAL SPECIFICATIONS 17 5.1 Clad Plates 17 5.2 Limitations on Thickness, and Weight 17 5.3 Certification 18 API 5L SPECIFICATION FOR LINE PIPE 19 ASME CODE REQUIREMENTS 20 7.1 BPVC Section I, Rules for Construction of Power Boilers [2] 20 7.2 BPVC Section IV, Rules for Construction of Heating Boilers [5] 20 7.3 BPVC Section VIII, Division 1, Rules for Construction of Pressure Vessels [6] 21 7.4 BPVC Section VIII, Division 2, Alternative Rules [7] 22 iii c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 7.5 BPVC Section VIII, Division 3, Alternative Rules for Construction of High Pressure Vessels [8] 23 7.6 BPVC Section XII, Rules for Construction and Continued Service of Transport Tanks [9] 24 7.7 ASME B31.1, Power Piping [11] 24 7.8 ASME B31.3, Process Piping [12] 24 FABRICATION EFFECTS 26 8.1 Forming 26 8.2 Postweld Heat Treatment (PWHT) of Ferrous Materials 26 8.2.1 PWHT Requirements 26 8.2.2 Test Coupons 27 8.2.3 PWHT Effect on Materials 27 8.3 Postweld Heat Treatment of Nonferrous Materials 27 MATERIALS DEGRADATION MECHANISMS 29 9.1 BPVC Section II, Part D [4], Appendix A 29 10 OTHER CODES AND STANDARDS, OR RECOMMENDED PRACTICES 30 10.1 API Recommended Practices for CR – MO Steels 30 10.2 API Recommended Practices to Avoid Damage in Certain Service Environments 30 10.3 NACE Standards 30 10.4 TAPPI TIPS 31 11 PAST MATERIALS PROBLEMS 32 11.1 All Product Forms 32 11.2 Plates 34 11.3 Forgings 36 11.4 Welded Pipe and Tubes 36 11.5 Castings 37 11.6 Use of Wrong Materials 37 12 VENDOR QUALIFICATIONS 38 12.1 Review of Vendor Procedures 38 12.2 Quality Control 38 12.3 Documentation 38 12.4 Materials Traceability 38 13 SUGGESTED MEASURES FOR ORDERING MATERIALS 39 13.1 Review of Materials Manufacturers and Suppliers’ Qualifications 39 13.2 Documentation 39 14 MATERIALS PURCHASE SPECIFICATIONS 40 14.1 Additional Considerations 40 References 41 APPENDIX A: SUGGESTED Materials Quality Control Programs for Material Manufacturers and Suppliers 43 APPENDIX B: SA-516, Grade 70 Plate Sample Material Procurement Specification 44 APPENDIX C: SA-387, Grade 11, Class Plate Sample Material Procurement Specification 46 iv c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials FOREWORD The scope of this document is to discuss the requirements in the ASME Codes and in the ASME material specifications for metallic materials, to address the various issues that affect the materials, and to provide guidelines for evaluating materials manufacturers and for preparing materials specifications that include the requirements for procuring material for ASME Code construction The author acknowledges, with deep appreciation, the following individuals for their technical and editorial peer review of this document: Jeffrey Henry, Dipak Chandiramani, Bryan Erler, Roy Grichuk, James Hall, David Jones, Mark Lewis, Adeel Raza, Christopher Reichert, Marcello Senatore, and Richard Sutherlin in particular, thanks to ASME staff for the assistance provided in the execution of this project Established in 1880, the American Society of Mechanical Engineers (ASME) is a professional not-forprofit organization with more than 135,000 members and volunteers promoting the art, science and practice of mechanical and multidisciplinary engineering and allied sciences ASME develops codes and standards that enhance public safety, and provides lifelong learning and technical exchange opportunities benefiting the engineering and technology community Visit www.asme.org for more information v c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials INTENTIONALLY LEFT BLANK vi c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials INTRODUCTION The ASME Boiler and Pressure Vessel Codes (BPVC) typically use ASME material specifications in practice, whereas, the ASME Piping Codes use ASTM material specifications The ASME material specifications used in BPVC construction are based on the American Society for Testing Materials (ASTM), American Welding Society (AWS), or other international material specifications for metallic materials The material specifications include mandatory requirements for manufacturing, testing and inspecting material, and may include a number of supplementary requirements, which are only used when specified by the purchaser The specifications may also contain requirements pertaining to ordering and supplying of the materials ASTM and ASME material specifications generally not include requirements that address fabrication effects on materials, except for statements that the material is suitable for welding construction The BPVC and the ASME B31 Pressure Piping Codes include certain requirements for fabrication effects, such as forming strains, tests on representative test coupons to simulate fabrication heat treatments, impact test requirements for materials and welded joints, and inspection requirements Where these additional requirements are mandated by the ASME Codes, it is generally the responsibility of the vessel or piping designer/purchaser to specify these requirements when specifying/purchasing raw materials The ASME Codes and the various material specifications also not generally include special requirements for environmental effects on the materials The 2013 edition of the BPVC Section II, Part D includes an expanded Non-mandatory Appendix A that describes various materials degradation mechanisms for materials that are used in ASME Code construction Generally, it is the responsibility of the user or designer to identify service related material requirements for vessels and piping It is the responsibility of the vessel or piping manufacturer to specify these requirements when procuring materials Frequently, ASME material requirements or service related conditions are not properly identified, or communicated between the parties involved during design, specification, procurement, and fabrication of vessels and piping, This document is intended to highlight common problems associated with the specification and procurement of materials for ASME Code construction The relevant ASME Codes in this document include BPVC Section I, BPVC Section IV, BPVC Section VIII, BPVC Section XII, B31.1 Power Piping Code (ASME B31.1), and B31.3 Process Piping Code (ASME B31.3) The information in this report may also be applicable to other codes; however, such other codes have not been evaluated for inclusion in this document c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials SCOPE The ASME Codes and material specifications include specific requirements for use of the materials in ASME Code construction However, they not address all requirements It is the responsibility of the user to specify service related requirements to prevent in-service degradation of the materials It is the responsibility of the vessel manufacturer to account for materials degradation during fabrication and to include all necessary requirements in the raw material purchase specifications for ASME Code construction The scope of this document is to discuss the requirements in the ASME Codes and in the ASME material specifications for metallic materials, to address the various issues that affect the materials, and to provide guidelines for evaluating materials manufacturers and for preparing materials specifications that include the requirements for procuring material for ASME Code construction Some of the sections in this document pertain only to ferrous materials (carbon steels, low alloy steels and high alloy steels) because many of the past problems have been related to these materials (refer to Section and Section 11 herein) However, most of the issues and considerations discussed in this document also pertain to nonferrous materials, particularly Sections 12 – 14 herein c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials ASME ADOPTION OF MATERIAL SPECIFICATIONS ASME material specifications are those that are published in the BPVC Section II, Parts A, B and C The majority of ASME material specifications are based on ASTM or AWS specifications ASME ferrous material specifications are identified by the letters “SA” as the first characters in the specification number For example, SA-106 refers to an ASME specification, whereas A106 refers to an ASTM specification ASME nonferrous material specifications are identified by the letters “SB” as the first characters in the specification number For example, SB-366 refers to an ASME material specification, whereas, B366 refers to an ASTM material specification ASME welding rod, filler metal, and electrode material specifications are identified by the letters “SFA” as the first characters in the specification number For example, SFA-5.1/SFA-5.1M refers to an ASME specification, whereas, A5.1/A5.1M refers to an AWS welding material specification As ASME adopts ASTM and other acceptable international material specifications for pressure vessel construction, the requirements in the ASME specification generally will be the same as those in the adopted ASTM or the acceptable international specification However, some of the ASME material specifications include a statement underneath the title of the specification that lists the exceptions from the ASTM (or international) specification, or additional ASME requirements Users should consult the appropriate specification to determine the differences between the ASME and the ASTM/AWS (or other international) specifications 3.1 ASME Material Specifications In general, materials used for ASME BPVC construction are required to be ASME materials The BPVC Section II, Part D, Tables 1A, 1B, 2A, 2B, C, 5A and 5B list all materials that may be used for ASME Code construction Materials that have a temperature listed in the column titled “Applicability and Maximum Temperature Limits” may be used for ASME Code construction within the indicated temperature range for the applicable BPVC Section Materials that have “NP” listed in this column may not be used for construction under that Section Materials that are not listed in the BPVC Section II, Part D, may be used for ASME Code construction if permitted by an ASME Code Case The materials used for ASME Code construction must be furnished in accordance with the specifications listed in BPVC, Section II The materials for Code use shall be ordered, produced, and documented in accordance with either the ASME specification in Section II (except as limited by the rules of the applicable construction code), or with an ASTM specification listed in Table II-200-1, or with a specification issued by other acceptable non-ASTM (international) specifications listed in Table II-200-2, or in a ASME Code Case for the construction code(s) listed in the ASME Code Case The ASME SA material specifications include a statement under the title of the specification that identifies the related ASTM or the international material specification Many ASME SA material specifications are identical with a particular edition of the same ASTM specification, in which case the ASME SA specification states that the ASME SA specification is identical with the ASTM or the international material specification, and lists the year date of the publication of that specification that is used for adoption of it as the ASME SA material specification However, not all of the ASME SA material specifications are identical with the ASTM or the related international material specification In such cases the statement under the title of the ASME SA specification also lists the exceptions, or modifications, or additional requirements to the adopted specification for use in ASME Code construction For example, the ASME SA specification SA-335 adds hardness requirements for Grades P23 and P911 pipes Another example is fusion welded pipes under specifications SA-671 and SA672 that include an additional statement that limit fabrication of such pipe for ASME Section III c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials temperature This required the use of a costlier welding process with lower heat inputs to meet the required impact test requirements (2) A/SA-737, Gr B permits a maximum Cb content of 0.05% by heat and by product analysis A vessel manufacturer purchased this material for low temperature service with impact test requirement of 20 ft-lb at -50 °F but was not able to meet the impact test requirement in welded joints after PWHT (in HAZ and in weld metal due to Cb pickup in weld metal by dilution with the base metal) The plates contained 0.05% – 0.06% Cb by product analysis The actual Cb contents in the plates caused loss of toughness in the HAZ and in the weld metal For certain applications, such as described above, the Cb content should have been restricted to a lower value than permitted by the SA-737 product specification, or a different material should have been considered for this application (3) A steel plate specification produced by one of the European countries permitted up to 0.18% vanadium for a normalized high strength steel and was typically supplied with more than 0.12% V content Tests on stress relieved welded joints indicated excessive loss of notch toughness (impact test values) in heat affected zones after PWHT (4) In another example, a stress relieved LPG sphere (in Far East) suffered extensive hydrogen induced cracking in heat affected zones, whereas an adjacent LPG sphere connected to the same LPG system did not The materials had similar strength, heat treatment, and chemical composition, except that the material in the sphere with cracks was a micro alloyed steel with Cb, and the other sphere did not contain any significant amounts Cb or V (5) Reports that indicate deliberate addition of boron to carbon steels being shipped to USA from international sources Boron decreases weldability and increases hardenability, which is undesirable for certain applications SA-20, Table now includes a maximum limit on boron content when it not one of the specified chemical components in the material specification (b) Surface Defects in Plates - Surface defects (such as blisters scabs, slivers, seams, pits), can be caused by improper pouring, casting, or rolling Surface and internal defects can also be caused by improper adjustments of the continuous caster and thermal gradients during continuous casting Mill scale can be caused during heat treatment and inadequate controls during rolling of the plate Mill scale hides surface defects Plates with mill scale should generally be descaled to permit proper surface inspection Of particular concern are low alloy nickel bearing plates (such as 9% Ni and 5% Ni plates), which typically have a thick tenacious mill scale after heat treatment “AISC Steel Plates Manual Plates, Rolled Floor Plates, Carbon, High Strength Low Alloy, and Alloy Steel” [1] includes photographs of various surface defects (c) Segregations and Laminations - Segregations and laminations are internal defects that are generally caused by inadequate control of process variables in melting, casting, and cutting These plate defects can render the plate unsuitable for fabrication (welding) or for use in structures Of particular concern are large laminations that are not parallel to plate surface These defects can increase crack propagation rates and the risk of brittle fracture In one example of this problem, two rail car manufacturers purchased large quantities of carbon steel plates from an international material manufacturer The plates met the product specifications ultrasonic testing acceptance criteria, but could not be welded because of an extensive amount of segregations at mid-thickness of the plate The materials manufacturer refused to accept any responsibility for the problem An independent investigation concluded that the segregations were the result of improper process controls with the continuous caster The rail car manufacturers rejected all plates from this material manufacturer and purchased new plates from another steel producer 35 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials (d) Edge Defects in Plates - Edge defects are caused by internal defects or cutting of plate edges They are undesirable because they can cause welding problems and leave defects in heat affected zones of welded joints, thereby increasing the risk of brittle fracture (e) Plates Produced From Coils - Plates produced from coils can have poor flatness, wavy edges, poor edge camber, welded splices, and distortions after cutting and welding because of locked up thermal stresses due to uneven cooling rates at ends, edges, and in the middle of the coil Vessel and storage tank constructors have experienced flat spots, poor appearance, and difficulties in meeting geometric tolerance requirements when using plates from coil, unless additional precautions are taken (e.g., temper rolling of the coil before cutting into plates) Plates from coils are also likely to have non-uniform properties, mainly due to unidirectional rolling and uneven cooling rates of the coiled product 11.3 Forgings (a) Use of Separately Forged Test Blanks for Forgings - Most forging specifications permit the use of separately forged test blanks instead of testing the forging, or a prolongation of the forging (with or without the use of thermal buffers) These specifications also require the separately forged test blanks to be reduced by forging in a manner similar to that of the forging itself, to receive approximately the same hot working and reduction, and the same heat treatment as the finished forging It is difficult to verify these requirements (particularly the amount of hot working), and consequently, the test results from the separately forged test blanks may not be representative of the actual forging In one case, a vessel and storage tank manufacturer had to reject a large amount of ASTM A350 Gr LF2 flanges (in one case about 1800 flanges) after they tested the flanges In each case, the test results from the separately forged test blanks had acceptable impact results at -50 °F (-46 °C), whereas the test results from the actual forgings had only a few ft-lbs (in some cases as low as ft-lbs at -50 °F) The product specification required at least 15 ft-lb at -50 °F (-46 °C) (b) Poor Weldability - Most forging specifications not specify limitations on unspecified elements This is also not covered in the general requirements specifications High levels of unspecified elements (such as columbium, vanadium, or boron) have been known to result in cracking problems due to insufficient preheat (c) Improper Use of Forging Specifications - Some forging specifications (e.g., SA-105, SA-182) are intended for piping applications and not for large and heavy forgings The following gives an example of misapplication of forging specifications In one case this resulted in costly rejection of thick SA-350 Gr LF2 tube sheets as the material was not capable of meeting the toughness requirement The SA-350 Gr LF2 tube sheets were replaced with SA- 765 Gr IV material, a forging specification that is generally intended for larger forgings than SA-350 11.4 Welded Pipe and Tubes Problems have been reported with low frequency welded ASTM A53 ERW pipe that have resulted in leaks during hydrostatic testing and expansion of the pipe These problems have been significantly reduced by use of high frequency Electric Resistance Welding (ERW) Also normalizing of the pipe after ERW improves the properties of the pipe Purchasers may want to restrict the use of A53 ERW piping to sizes NPS and larger, where full examination of the weld seam is required by the manufacturer A 178 and SA-178 includes a supplementary requirement S1 that have provisions UT examination of the ERW pipe 36 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 11.5 Castings (a) Product Quality - Several purchasers and users have encountered problems with valves One user encountered leaks in several castings during hydrostatic tests or in service These were attributed to improper casting practices (e.g., pouring the casting too fast or letting it cool too fast), resulting in shrinkage cracks, improper heat treatment, and welded repairs Another user purchased 90 control valves of which 63 were recalled by the vendor The problems included casting defects, lack of control of manufacturing procedures leading to improper assembly, and lack of proper QA/QC records A construction company purchased 620 valves from a supplier The valves were produced by a valve manufacturer in Asia Many of the cast valves were unsound and leaked which led to all valves to be rejected and replaced (b) Cracks - Surface flaws have been detected by magnetic particle testing that, when explored further, have resulted in large repairs In one case these flaws were attributed to segregation of tramp elements (typically Pb, Sn, Sb, As, P, and S) at the solid/liquid interface, usually at the top of the casting during pouring, which resulted in very tight cracks between the final casting grains (c) Welded Repairs - The casting manufacturer should not perform welded repairs unless permitted by the product specification and unless approved by the purchaser However, welded repairs have been reported where the repairs were made without the knowledge of the purchaser, by unqualified welders, and were masked by paint In one case the casting passed the hydrostatic test but later failed in high pressure high temperature service 11.6 Use of Wrong Materials In some cases wrong materials have been supplied and wrong welding materials have been used for welding of vessel components This could lead to failures when used in certain service conditions Of particular concern are materials in high or low temperature service and if used in service environments that can cause embrittlement and cracking In one case, carbon steel welding material was inadvertently used for welded joint in a Cr-Mo vessel in high temperature service that could have resulted in premature failure Positive material identification after completion of fabrication using portable field equipment identified the weld as carbon steel, which was replaced with the appropriate Cr-Mo material 37 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 12 VENDOR QUALIFICATIONS Most of the materials problems discussed in Section 11 of this report could have been avoided by the following: (a) Use reliable and approved materials manufacturers and suppliers (b) Review of Vendor Procedures (c) Manufacturers implementing a Materials Quality Control Program that is audited by the Purchaser or Purchaser’s representative (d) User’s Design Specification (as required by the appropriate Construction Code) (e) Materials Purchase Specification, as outlined in Section 14 of this report Several organizations have in-house requirements that require qualification of materials manufacturers for supply of materials for pressure vessel and piping construction These programs generally require a survey of materials manufacturers’ facilities, manufacturing processes and procedures They typically also require a review of past production data, testing, inspection practices, and quality control 12.1 Review of Vendor Procedures Review of vendor procedures typically includes evaluation of manufacturer’s or supplier’s (distributor’s) facility, capabilities, manufacturing procedures, inspection practices, record keeping, documentation, and quality control 12.2 Quality Control Materials manufacturers and suppliers should have quality control procedures that ensure the following: (a) The materials comply with the quality and quality control requirements in the applicable codes and standards (b) The material is produced in accordance with a specific revision of a product specification, and the manufacturer is in possession of that revision of the product specification (c) The quality control measures in the purchaser’s documents are being carried out (d) The documentation accurately reports the results of all testing and inspection (e) The material meets all purchaser requirements (f) The material contains all necessary markings A suggested materials quality program for materials manufacturers and suppliers is provided in Appendix A to this report 12.3 Documentation The materials manufacturer or processor must be able to provide documentation that the material meets all the applicable specification and purchaser requirements The test reports shall report the results of all required tests, types of heat treatments, and any additional purchaser requirements All documents shall be traceable to the purchase order 12.4 Materials Traceability The materials manufacturer shall provide documentation and marking of materials that insure conformance with the purchase requirements and traceability to the purchase order 38 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 13 SUGGESTED MEASURES FOR ORDERING MATERIALS 13.1 Review of Materials Manufacturers and Suppliers’ Qualifications (a) Perform site evaluation of manufacturer’s or supplier’s facility, capabilities, manufacturing processes and procedures, inspection practices, past production data, record keeping, documentation, and quality control (b) Use materials manufacturers that have demonstrated experience and have a proven track record in the production of desired pressure vessel materials that have the necessary quality controls for their manufacturing processes, and that have quality control system based on generally accepted principles (c) Use vendors that meet the qualifications in Section 12, above, including vendor procedures, quality control and documentation, and traceability of materials (d) Develop an “approved” manufacturers or suppliers list (e) Perform on-site inspection during and after material production and component fabrication Impose stringent initial checks and inspections, which may be relaxed to permit less frequent spot checks as the manufacturer demonstrates their reliability Use third party inspection where appropriate (f) Use material purchase specifications to clearly specify all applicable Code requirements and any additional Purchaser or User requirements as outlined in Section 14 of this report 13.2 Documentation The materials manufacturer or processor must provide documentation that indicates that the material meets all the applicable specification and purchaser requirements When required by the purchase order, or required by the product specification, the materials manufacturer shall produce a certified test report The test reports shall report the results of all required tests, types of heat treatment, and of any additional purchaser requirements The purchaser is expected to specify any additional requirements (examinations, testing, or additional restrictions on chemical composition, etc.) that are important for the intended use of the material 39 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 14 MATERIALS PURCHASE SPECIFICATIONS ASME Codes and standards only contain minimum requirements These should be supplemented, as necessary, by additional requirements from the ASME material specifications and user defined documents, as stated below: (a) Heat treatments, including fabrication heat treatments - Test specimens should be tested to simulate all fabrication heat treatments, as required by the ASME Codes, or whenever the fabrication heat treatments may result in loss of notch toughness (e.g., high PWHT temperatures, or long hold times at the PWHT temperature) (b) Notch toughness requirements and testing - Consideration should be given to increasing the notch toughness requirements in the Purchase specifications where the fabrication procedures may result in loss of notch toughness (e.g., high heat input welding may cause loss of toughness in the heat affected zones, or cold forming strains may result in loss of toughness, etc.) (c) Test specimens (e.g., amount, location and orientation in plates, forgings, pipe and fittings) (d) Maximum carbon equivalents for improved weldability (e) Restrictions on chemical composition (unspecified elements, J-factors for Cr-Mo steels to reduce the risk of temper embrittlement or creep embrittlement, as applicable, etc.) (f) Plate surface conditioning (e.g., descaling) (g) Examination (UT examination of plates and cladding, UT examination of forgings, MT or PT of machined surfaces of forging, etc.) (h) Repair welding (i) Documentation (j) Positive Materials Identification (PMI) 14.1 Additional Considerations (a) Request MTRs for all materials, including those materials whose specifications that permit material to be supplied with COCs (b) Perform random Nondestructive Examination (NDE), hardness, ferrite (for stainless steel), chemical composition, and other destructive and nondestructive (e.g., tensile, impact) testing for verification of material compliance with the specification requirements (c) Perform additional tests, including welding tests, to assess the effect of fabrication on the material and to ensure that the material will meet the project requirements (d) Perform additional testing of new materials to determine the effect of fabrication heat treatments and service conditions Sample material procurement specifications are included in Appendices B and C to this document These specifications list additional requirements that were specified for specific projects that included additional considerations for those projects, in addition to the ASME BPVC, Section VIII, Division requirements 40 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] AISC Steel Products Manual, Plates, Rolled Floor Plates, Carbon, High Strength Low Alloy, and Alloy Steel BPVC Section I, Rules for Construction of Power Boilers BPVC Section II, Part A, Ferrous material Specifications BPVC Section II, Part D, Properties BPVC Section IV, Rules for Construction of Heating Boilers BPVC Section VIII, Division 1, Rules for Construction of Pressure Vessels BPVC Section VIII, Division 2, Alternative Rules for Construction of Pressure Vessels BPVC Section VIII, Division 3, Alternative Rules for Construction of High Pressure Vessels BPVC Section XII, Rules for Construction and Continued Service of Transport Tanks ASME B16.5, Pipe Flanges and Flanged Fittings ASME B31.1, Power Piping ASME B31.3, Process Piping Comparison of ASME Specifications and European Standards for Mechanical Testing of Steels for Pressure Equipment, E Upitis and M Gold, ASME Standards Technology, LLC., December 16, 2005 API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining and Petrochemical Industries API RP 934, Materials and Fabrication of 2¼ Cr-1Mo, 2¼ Cr-1Mo-1/4 V, 3Cr-1Mo, 3Cr-1Mo¼V Steel Heavy Wall Pressure Vessels for High Temperature, High Pressure Hydrogen Service API TR 934B, Fabrication Considerations for ¼ Vanadium Steel Heavy Wall Pressure Vessels for High Temperature, High Pressure Hydrogen Service API RP 934C, Materials and Fabrication of 1¼ Cr-1/2 Mo Steel Heavy Wall Pressure Vessels for High Pressure Hydrogen Service Operating at or Below 825 ⁰F (441 ⁰C) API TR 934D, Technical Report on the Materials and Fabrication Issues of 1ẳ Cr ẵ Mo and Cr – ½ Mo Steel Pressure Vessels API RP 934E, Recommended Practice for Materials and Fabrication of 1¼ Cr-1/2 Mo Steel Pressure Vessels for Service above 825 ⁰F (441 ⁰C) API RP 941, Steels in Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and Petrochemical Plants API RP 945, Avoiding Environmental Cracking in Amine Units NACE 8X194, Materials and Fabrication Practices for New Pressure Vessels Used in Wet H2S Refinery Service NACE SP0403, Avoiding Caustic Stress Corrosion Cracking of Carbon Steels Refinery Equipment and Piping NACE SP0472, Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments WRC Bulletin 488, Damage Mechanisms Affecting Fixed Equipment in the Pulp and Paper Industry, January 2004 WRC Bulletin 489, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, February 2004 41 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials [27] [28] [29] [30] NACE 8X194, (2006 Edition), Materials and Fabrication Practices for New Pressure Vessels Used in Wet H2S Refinery Service WRC Bulletin 490, Damage Mechanisms Affecting Fixed Equipment in the Fossil Electric Power Industry, April 2004 ISO/TS 29001:2010, Petroleum, petrochemical and natural gas industries – Sector specific quality management systems – Requirements for product and service supply organizations BPVC Section III, Subsection NCA, General Requirements for Division and Division 2, NCA-3800 42 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials APPENDIX A: SUGGESTED MATERIALS QUALITY CONTROL PROGRAMS FOR MATERIAL MANUFACTURERS AND SUPPLIERS The Materials Manufacturers and suppliers should have a Materials Quality Control Program that at least satisfies the requirements of ISO 9001 and includes the following provisions: (a) The Materials Manufacturer shall certify that all requirements of the applicable material specifications and all supplementary requirements specified by the Purchaser have been complied with The certification shall consist of Materials Manufacturer’s certified materials test report showing numerical results of all required tests, and shall certify that all required examinations and repairs have been performed on the materials (b) Materials Manufacturers and suppliers (distributors) shall have a Quality Control Manual that describes the specific activities in their facilities, including the following: (1) Operations performed during the melting, refining, chemical analysis, conversion from one product form into another product form, including dimensional requirements and certification to the applicable material specification (2) Testing, examination, repair, or treatments required by the material specification and the purchaser, and certification of the results of all tests, examinations, repairs, or treatments (3) Receipt, identification, verification, handling, storage, and shipment of material or source material (c) The persons responsible defining and measuring the effectiveness of the program shall: (1) Be sufficiently independent from the pressures of the production (2) Have direct access to the responsible management at a level where appropriate action can be initiated (d) Persons or organizations responsible for assuring that the Quality Control Program has been established and verifying that that activities affecting quality have been correctly performed shall have sufficient authority, access to work areas, and organizational freedom to: (1) Identify quality problems (2) Initiate, recommend, or provide solutions to quality problems through designated channels (3) Verify implementing of the solution (4) Ensure that further processing, delivery, or use is controlled until proper disposition of a nonconformance, deficiency, or unsatisfactory condition has occurred (e) Management shall regularly review the status and adequacy of the program (f) Quality Control Manual The Quality Control Program shall be described and summarized in a Quality Control Manual (g) Quality Control Records Records that furnish documentary evidence of quality shall be specified, prepared, controlled, and maintained (h) Control of Purchased Materials, source materials, and services, including welding materials (i) Approval and Control of Suppliers of Source Material (j) Procurement Document Control (k) Process Control (melting, casting, rolling, heat treatment, examination, testing, dimensional control, repairs, testing, marking, etc.) (l) Control of Examinations, Tests, and Nonconforming Material (m) Material Identification and Certification (n) Welded Repairs Welded repairs should not be permitted on any material without the approval by the purchaser The purchaser should have the right of review and approval of all welding and heat treatment procedures prior to the granting approval (o) The materials quality control program should have provisions for periodic audits 43 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials APPENDIX B: SA-516, GRADE 70 PLATE SAMPLE MATERIAL PROCUREMENT SPECIFICATION 1.0 SCOPE This specification includes the requirements for SA-516, Grade 70 plates for use in sour service 2.0 REFERENCED STANDARDS AND SPECIFICATIONS The latest editions of the codes and standards listed below shall be used: 2.1 ASME SA-516, Standard Specification for Pressure Vessel Plates, Carbon Steel for Moderateand Lower Temperature Service 2.2 ASME SA-20, Specification for General Requirements for Steel Plates for Pressure Vessels 2.3 ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, Rules for Construction of Pressure Vessels 2.4 ASME SA-578, Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications 3.0 MATERIAL 3.1 The plates shall meet all requirements of ASME SA-516, Grade 70, the specifications referenced in 2.1 – 2.4, above, and the additional requirements of this specification 3.2 Applicable SA-20 Supplementary Requirements: 3.2.1 S1 Vacuum Degassing 3.2.2 S19 Restricted Chemical Requirements 3.2.3 S20 Maximum Carbon Equivalent for Weldability 3.3 Applicable SA-578 Supplementary Requirements: S1 Scanning 4.0 MANUFACTURE 4.1 The plate material shall be vacuum degassed steel 4.2 The plates shall be normalized 5.0 CHEMICAL COMPOSITION Plate shall meet the following additional chemical composition requirements (weight percent) by heat analysis: 5.1 Phosphorus (P) content: 0.010% max 5.2 Sulfur (S) content: 0.006% max 5.3 Columbium (Cb), Vanadium (V), titanium (Ti), and Boron (B) contents shall not exceed the values in SA-20, Table Footnotes C, D, and E to SA-20, Table shall not be applicable 5.4 The maximum carbon equivalent (CE) shall be 0.45% by heat and product analysis 6.0 HEAT TREATMENT 6.1 The plates shall be normalized 7.0 MECHANICAL TESTING 7.1 Charpy V-Notch Impact Testing 44 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 7.1.1 The Charpy V-notch test temperature shall be -20 ºF 7.1.2 The average absorbed energy value of the impact test specimens shall be 15 ft-lbs, and no single specimen shall have a value less than 12 ft-lbs The retest procedures of ASME SA-20 shall apply 8.0 INSPECTION 8.1 Ultrasonic Examination Plates shall be 100% ultrasonically examined in accordance with ASME SA-578, Acceptance Level C 9.0 REPAIR OF DEFECTS 9.1 No repair welding is permitted without prior approval by the purchaser The plate manufacturer shall submit the repair welding procedures to the purchaser for approval prior to any repair welding 10.0 CONFLICTING REQUIREMENTS Any apparent conflict between the requirements listed in this specification and the applicable ASME Specifications shall be submitted to the Purchaser for clarification 11.0 CERTIFICATION 11.1 The plate manufacturer shall provide certified mill test reports in accordance with ASME SA-20 45 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials APPENDIX C: SA-387, GRADE 11, CLASS PLATE SAMPLE MATERIAL PROCUREMENT SPECIFICATION 1.0 SCOPE This specification includes the requirements for ẳ Cr ẵ Mo plates for use in a pressure vessel in elevated temperature service The maximum plate thickness is 1¾ in (45 mm) 2.0 REFERENCED STANDARDS AND SPECIFICATIONS The latest editions of the codes and standards listed below shall be used: 2.1 ASME SA-387, Standard Specification for Pressure Vessel Plates, Alloy Steel, ChromiumMolybdenum 2.2 ASME SA-20, Specification for General Requirements for Steel Plates for Pressure Vessels 2.3 ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, Rules for Construction of Pressure Vessels 2.4 ASME SA-578, Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications 2.5 API RP 934-E, Recommended Practice for materials and Fabrication of 1ẳCrẵMo Steel Pressure Vessels for Service above 825 ºF (441 ºC) 2.6 ASNT SNT-TC-1A, Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing 3.0 MATERIAL 3.1 The plates shall meet all requirements of ASME SA-387, Grade 11, Class 1, the specifications referenced in 2.1 – 2.6, above, and the additional requirements of this specification 3.2 Applicable SA-20 Supplementary Requirements: 3.2.1 S1 Vacuum Degassing 3.2.2 S3 Simulated Post-Weld Heat Treatment of Mechanical Test Coupons 3.2.3 S5 Charpy V-notch Impact Tests 3.2.4 S19 Restricted Chemical Requirements 3.3 Applicable SA-387 Supplementary Requirements: S53 Alternative Location for Mechanical Testing 3.4 Applicable SA-578 Supplementary Requirements: S1 Scanning 4.0 MANUFACTURE 4.1 Plates shall be produced to fine grain practice 4.2 The plate material shall be vacuum degassed steel 5.0 CHEMICAL COMPOSITION Plate shall meet the following additional chemical composition requirements (weight percent) by heat analysis: 5.1 Carbon (C) content: 0.13% max 5.2 Phosphorus (P) content: 0.005% max 46 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 5.3 Sulfur (S) content: 0.007% max 5.4 Tin (Sn) content: 0.015% max 5.5 Copper (Cu): 0.20% max 5.6 Nickel (Ni): 0.30% max 5.7 Columbium (Cb), Vanadium (V), titanium (Ti), and Boron (B) contents shall not exceed the values in SA-20, Table Footnotes C, D, and E to SA-20, Table shall not be applicable 5.8 X-bar Factor: 15 max., where X-bar factor = (10P+5Sb+4Sn+As)/100, and P, Sb, Sn, and As are in PPM 6.0 HEAT TREATMENT 6.1 Plate shall be normalized and tempered (NT) The tempering temperature shall be 1300 ºF minimum 6.2 The test coupons shall be heat treated to simulate stress relieving by heating uniformly to a temperature of 1275 ºF (±10 ºF) The maximum hold time, hours, at 1275 ºF shall be as specified by the vessel manufacturer This shall include at least three PWHT cycles at 1275 ºF and all intermediate PWHT cycles needed for the vessel fabrication The rate of heating and cooling shall conform to the ASME Code Section VIII, Division 1, paragraph UCS-56, except that above 800 ºF, the cooling rate shall not exceed 100 ºF per hour 6.3 Test coupons representing the plate that has been weld repaired by Purchaser’s agreement shall receive the additional PWHT specified in paragraph 6.2, above 7.0 MECHANICAL TESTING 7.1 Tension Tests 7.1.1 The test specimens for tension testing shall be in accordance with SA-20 7.1.2 Test coupons shall be heated to represent the maximum post-weld heat treatment per paragraphs 6.2 and 6.3 of this specification 7.2 Charpy V-Notch Impact Testing The test specimens shall be oriented transverse to the major direction of rolling of the plate 7.2.1 The Charpy V-notch test temperature shall be -20 ºF, or a colder temperature 7.2.2 The test coupons shall be heat treated to represent both the minimum and maximum post-weld heat treatments the equipment are expected to receive during the fabrication (see paragraphs 6.2 and 6.3) 7.2.3 The average absorbed energy value of the impact test specimens shall be 40 ft-lbs, and no single specimen shall have a value less than 20 ft-lbs The retest procedures of ASME SA-20 shall apply 7.2.4 The percent shear and appearance and mils lateral expansion (MLE) shall be reported for information 8.0 INSPECTION 8.1 Ultrasonic Examination Plates shall be 100% ultrasonically examined in accordance with ASME SA-578, Acceptance Level C 8.2 Qualification of NDE Personnel 8.2.1 All NDE personnel and personnel interpreting and reporting results shall be qualified in accordance with ASNT Recommended Practice No SNT-TC-1A 47 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME PTB-8-2014: Procurement Guidelines for Metallic Materials 9.0 REPAIR OF DEFECTS 9.1 No repair welding is permitted without prior approval by the purchaser The plate manufacturer shall submit the repair welding procedures to the purchaser for approval prior to any repair welding 9.2 Welded repairs requiring metal excavation 3/8” or less in depth shall be inspected by magnetic particle examination (MT) or by liquid penetrant examination (PT) Repairs deeper than 3/8” shall be inspected by using purchaser approved radiographic procedure 9.3 All welded repairs shall be made prior to final post-weld heat treatment (PWHT) The additional time for weld repairs shall be added to the time for test coupons in paragraph 6.2 of this specification 9.4 Weld metal in welded repairs shall meet the following additional chemical composition requirements: 9.4.1 Carbon content: 0.10% max 9.4.2 Copper (Cu): 0.20% max 9.4.3 Nickel (Ni): 0.30% max 9.4.4 X-bar Factor: 12 maximum (see Paragraph 5.8, above) 9.4.5 Low hydrogen welding consumables, including fluxes, having a maximum of ml of diffusible hydrogen for every 100 g of weld metal, per AWS A4.3, shall be used 10.0 POSITIVE MATERIAL IDENTIFICATION The plates shall receive positive material identification before shipment to the purchaser 11.0 CONFLICTING REQUIREMENTS Any apparent conflict between the requirements listed in this specification and the applicable ASME Specifications shall be submitted to the Purchaser for clarification 12.0 CERTIFICATION 12.1 The plate manufacturer shall provide certified mill test reports in accordance with ASME SA-20 12.2 The certified mill test reports shall list the results of the chemical analysis of all elements listed in SA-387 for Grade F11 and the additional elements listed in Section 5.0 of this specification, determined by heat analysis and/or product analysis, as required by this specification 48 c Copyright 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME ASME PTB-8-2014 A26014 Copyright c 2014 by the American Society of Mechanical Engineers No reproduction may be made of this material without written consent of ASME